Tensioner For Flexible Drives

ABSTRACT

A tensioner in accordance with the present invention employs a spindle and a tensioner arm which are preferably manufactured by a suitable manufacturing process, such as die casting, negating a requirement for machining operations. The biasing spring of the tensioner is wound with wire having a non-circular cross section to increase the spring force of the spring compared to a similar spring wound with wire of circular cross section and, as the tensioner arm is moved away from the flexible drive, the diameter of the biasing spring expands and the coils press a dampening shoe into contact with a wall of the tensioner arm producing a dampening force. The tensioner is simple to assemble and requires a relatively small package volume for the biasing force it can produce.

FIELD OF THE INVENTION

The present invention relates to tensioners for flexible drives. Morespecifically, the present invention relates to tensioners with a reducedpackage volume, reduced manufacturing costs and/or simplified assembly.

BACKGROUND OF THE INVENTION

Tensioners for flexible drive systems, and in particular for flexibledrive systems comprising accessory drive systems on internal combustionengines, are well known. Such tensioners include a pulley which isbiased toward the flexible drive, typically a rubber belt. The pulley ismounted to an arm which is biased towards the flexible drive (thetensioning direction) by a spring and the arm can also include means toproduce a dampening force to inhibit oscillation of the arm and/orflexible drive.

While such tensioners are well known, they suffer from disadvantages inthat they can be relatively large, requiring significant availablemounting volume (package volume) on the engine or other device on whichthey are installed.

Further, while dampening the movement of the tensioner arm away from theflexible drive (the de-tensioning direction) to reduce oscillation isdesired, dampening movement of the tensioner arm toward the flexibledrive (the tensioning direction) inhibits the ability of the tensionerto maintain tension in the flexible drive and thus is undesired.

Also, prior art tensioners which provide frictional dampening typicallyprovide a substantially constant frictional force, independent of theamount of displacement of the tensioner arm. In contrast, it is desiredthat the frictional dampening force increase as the tensioner arm ismoved away from the flexible drive (the de-tensioning direction), ratherthan being a constant force.

Further still, the manufacture and assembly of conventional tensionerscan be involved, requiring machining operations on some parts andspecial assembly tools with multiple assembly steps, increasing themanufacturing expense of the tensioners.

It is desired to have a tensioner which can provide relatively hightensioning forces while requiring a relatively small package volume andwhich can be relatively easily manufactured and assembled.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a novel tensionerfor a flexible drive which obviates or mitigates at least onedisadvantage of the prior art.

According to a first aspect of the present invention, there is provideda tensioner for tensioning a flexible drive. The tensioner has a spindleand a tensioner arm. The spindle has a base is configured for mountingon a surface of an engine. The tensioner arm is mounted on the spindlefor rotatable movement about a first axis. The tensioner arm has apulley rotatably mounted about a second axis, the first axis beingspaced from and parallel to the second axis. A biasing coil spring actsbetween the spindle and the tensioning arm urging the tensioner arm torotate about the first axis in a tensioning direction and bias thetensioner arm and the pulley into tensioning, engagement with a flexibledrive. A bushing is mounted between the tensioner arm and spindle toallow the tensioner arm to pivot about the spindle and provide a firstfrictional force dampening movement of the tensioner arm about thespindle. A dampening shoe is mounted between the spring and thetensioner arm. The dampening shoe is urged into and out of frictionallyengagement with the tensioner arm when coils of the spring expand andcontract, respectively providing a varying second frictional force. Thefirst frictional force and the second frictional force sum together andprovide a tensioner with variable damping.

Preferably, the tensioner arm is die cast and includes a cast inclinedportion to receive the end surface of the biasing spring and alsoincludes a cast stop against which the end of the biasing spring abuts.Also preferably, the spindle is die cast and includes a cast stopagainst which the end of the biasing spring abuts. Also preferably, thedampening shoe includes a molded inclined portion to receive the helicalsurface of the biasing spring. Also preferably, the frictional forceprovided by the dampening shoe increases as the tensioner arm is movedfrom the first position. Also preferably, the frictional force rapidlydiminishes as the tensioner arm returns to the first position.

The present invention provides a tensioner which employs a spindle and atensioner arm which are preferably manufactured by die casting orsimilar manufacturing techniques, negating a requirement for machiningoperations. The biasing spring of the tensioner preferably includescoils formed from wire having a non-circular cross section to increasethe spring force of the spring compared to a similar spring with coilsof wire having a circular cross section. As the tensioner arm and pulleyare moved in the de-tensioning direction, away from the flexible drive,the diameter of the spring expands and the coils press at least aportion of a dampening shoe into contact with a wall of the tensionerarm producing a dampening force.

The tensioner is simple to assemble and requires a relatively smallpackage volume for the biasing forces and dampening forces it canproduce.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention will now be described, byway of example only, with reference to the attached Figures, wherein:

FIG. 1 is an exploded view showing the bottom and side of a tensioner inaccordance with the present invention;

FIG. 2 is an exploded view showing the top and side of the tensioner ofFIG. 1;

FIG. 3 is a side perspective view showing a portion of a tensioner arm,biasing spring and bushing of the tensioner of FIG. 1;

FIG. 4 is cross section taken through line 4-4 of FIG. 3;

FIG. 5 is a side perspective view of an assembly of the biasing springand bushing of the tensioner of FIG. 1;

FIG. 6 is a cross section taken along line 6-6 of FIG. 1;

FIG. 7 is an exploded view showing the top and side of another tensionerin accordance with the present invention;

FIG. 8 is an exploded view showing the bottom and side of the tensionerof FIG. 7;

FIG. 9 shows a bottom and side perspective view of a tensioner arm and abushing of the tensioner of FIG. 7;

FIG. 10 shows a top and side perspective view of a spindle, the bushingand a dampening shoe of the tensioner of FIG. 7;

FIG. 11 shows a cross section of the assembled tensioner taken alongline 11-11 of FIG. 8; and

FIG. 12 shows a plot of the force on the tensioner arm of FIG. 1 versusthe displacement of the tensioner arm.

DETAILED DESCRIPTION OF THE INVENTION

A tensioner for a flexible drive, in accordance with the presentinvention, is indicated generally at 20 in FIGS. 1, 2 and 6. Tensioner20 comprises a tensioner arm 24 to which a pulley 28 is rotatablymounted via a bolt 32 and a bearing 36, defining a first axis ofrotation. Bolt 32 engages a threaded fastener 33 formed in or attachedto the tensioner arm 24 at one end thereof. Bearing 36 can be integrallyformed in pulley 28 or can be a separate bearing installed on pulley 28.Pulley 28 can be designed to tension an endless rubber belt, eithersmooth or toothed, a chain or other flexible endless drive.

Tensioner 20 further includes a conical spindle 44 having a basecomprising a spindle cup 40 and an outer radial wall 48, which ispreferably somewhat conical in shape, as best seen in FIG. 6. Spindlecup 40 can include one or more index features or protrusions 52 on theouter bottom or mounting surface which engage complementary features onthe engine or other surface to which tensioner 20 is mounted to ensurethe correct orientation of tensioner 20 with respect to the flexibleendless drive to be tensioned. Spindle cup 40 can further include one ormore stops or protrusions 56 which is received within recess 57 oftensioner arm 24, limiting travel of tensioner arm 24 relative to thespindle 44 to between 30° and 60°, with 40° being most preferable.

Spindle cup 40 nestingly receives a bushing 60, best seen in FIGS. 3, 4and 5. Bushing 60 includes at least one index feature or protrusion 64which engages a complementary index feature or recess 67 in wall 48 ofspindle cup 40 to prevent rotation of bushing 60 with respect to spindlecup 40.

As illustrated, bushing 60 includes an annular lip 68, a somewhatconical radial wall 72 and a dampening structure, in this embodiment adampening shoe or ring 76, located radially inwardly from radial wall80. Bushing 60 can be fabricated from any suitable low friction, wearresistant organic resinous material, such as Nylon 4/6 (such as StanylTW363) and can be formed by injection molding or any other suitablemanufacturing process. The coefficient of friction of the bushing 60 canbe modified as desired by adding filler materials such as glass,graphite or by adding lubricants such as PTFE resins, dry lubricants,etc.

Annular lip 68 of bushing 60 is sized to extend over the upper edge ofthe spindle cup 40. Radial wall 72 is the friction surface between thetensioner arm 24 and the spindle 44. Radial wall 72 is asymmetrical anddoes not extend completely about annular lip 68. Preferably, radial wall72 extends arcuately having an arc length of about a half circle.

Dampening shoe 76 is flexibly attached to wall 72 by spaced radial tabs73 which simplifies manufacturing of the dampening shoe 76 and wall 72in a single mold cavity. Dampening shoe 76 has a series of tabs 77 and79 on the inner surface that collectively presents a spiral or helicalsurface for receiving the first coil of the coil spring 84. The endaxial surface of the shoe 76 has an indexing protrusion 164 and isinserted into aperture 65 on the bottom surface of the spindle cup 40.Preferably dampening shoe 76 is asymmetrical and does not extendcompletely about annular lip 68. Preferably, the friction surface ofdampening shoe 76 extends arcuately having a maximum arc length of abouta half circle. By limiting the maximum arc length, the dampening shoe 76generates frictional dampening forces rather than acting as a clutch.

Bushing 60 and dampening shoe 76 are positioned relative to thetensioning arm 24 and the biasing spring 84 such that both the hubloadforce vector and the reactionary spring force vector are directed in thesame direction through the bushing and dampening shoe 76. Thereactionary spring force vector acts in a direction of about 90° fromthe spring stop, abutment feature 89 on the spindle 44.

As best seen in FIGS. 2, 3 and 5, tensioner arm 24 includes at anopposite end, a hub 80, defining a second axis of rotation, preferablyhaving a complementary conical shape to that of outer radial wall 48,which extends orthogonally to the long axis of arm 24. The first axis ofrotation is spaced from and parallel to the second axis of rotation. Hub80 is received within radial wall 72 of bushing 60 when tensioner 20 isassembled. While the illustrated embodiment has a generally conical hub80 and radial outer wall 48, the present invention is not limited toconical shapes and can also include cylindrical shapes.

Tensioner 20 includes a biasing spring 84 which surrounds spindle 44 andacts between spindle cup 40 and tensioner arm 24 to bias tensioner arm24, and pulley 28, into tensioning engagement with the flexible drivetensioned by tensioner 20. Preferably, spring 84 is formed of wire coilswith a non-round cross-section, preferably rectangular, and has flatends. Tensioner arm 24 includes an abutment feature 88 extendingradially inwardly that receives one end of spring 84 and supports thehelical or spiral surface of the next adjacent coil of the spring 84 inan inclined manner. Spindle cup 40 also includes an abutment feature 89on the inner bottom surface that receives the opposite end of spring 84to transfer the bias force from spring 84 to tensioner arm 24 andspindle cup 40.

The helical or spiral surfaces that support the biasing spring 84enables the biasing spring 84 to expand and contract radially whilemaintaining general axial alignment of the coils of the biasing spring84. The coils of the biasing spring 84 will expand and contractuniformly to engage and disengage the bushing 60 and dampening shoe 76.Uniform expansion and contraction minimizes uneven contact and wear ofthe bushing 60 and/or the dampening shoe 76.

Tensioner 20 further includes a thrust washer 92 and a front plate 96which are assembled, as shown in FIGS. 1 and 2 with spindle 44 beingstaked to front plate 96 to retain tensioner arm 24 on spindle 44. Tomount tensioner 20 to an engine or other device, a bolt can be insertedthrough the center bore in spindle 44, thrust washer 92 and front plate96.

When tensioner arm 24 is subjected to a load, by the flexible drive itis tensioning, the outer surface of hub 80 rides on the inner surface ofradial wall 72 of bushing 60, transferring the load, i.e. the hubloadvector, to spindle cup 40. The relatively large surface areas of hub 80and radial wall 72 allow for relatively large loads to be transferredfrom tensioner arm 24 to spindle cup 40 while avoiding undue wear on thecomponents of tensioner 20.

Further, by appropriately selecting the material from which bushing 60is fabricated, the coefficient of the frictional force created betweentensioner arm 24 and spindle cup 40 can be selected and this frictionalforce acts as a desirable dampening force in the operation of tensioner20.

In addition to the dampening force created between hub 80 and radialwall 72, dampening shoe 76 of bushing 60 can dimensioned radially andcircumferentially to generate a desired dampening force betweentensioner arm 24 and spindle cup 40.

When tensioner arm 24 is moved in the de-tensioning direction (away fromthe flexible drive it is tensioning), spring 84 resists the movement oftensioner arm 24 by unwinding and the coils of spring 84 expand radiallyoutwardly and press against dampening shoe 76. The resulting forceexerted by the coils of spring 84 on dampening shoe 76 biases dampeningshoe 76 into greater frictional contact with the inner surface of hub 80thus squeezing hub 80 between radial wall 72 and dampening shoe 76.

This squeezing action adds another component of frictional forceinhibiting movement of tensioner arm 24 in the de-tensioning direction,further dampening movement of tensioner arm 24, and this frictionalforce varies with the expansion of the coils of spring 84, thus varyingdependent upon the amount of rotation of tensioner arm 24. In otherwords, the frictional force increases as the tensioner arm 24 movesfurther in the de-tensioning direction and thereby limiting movement ofthe tensioner arm 24.

Further, as tensioner arm 24 moves in the tensioning direction (toreturn to its original position) the radius of the coils of spring 84decreases, reducing the above-mentioned squeezing action such that theresulting frictional force has a different characteristic than thatexperienced by tensioner arm 24 when moving in the de-tensioningdirection.

As is apparent to those skilled in the art, the tensioner of the presentinvention can be tailored and tuned to meet the demands of any engineconfiguration.

Another tensioner for a flexible endless drive is indicated generally at200 in FIGS. 7, 8 and 11. Tensioner 200 includes a spindle 204 with abase 208 that can engage a surface of an internal combustion engine orother device on which the flexible drive to be tensioned is located.Base 208 can include a tang or other indexing feature to permittensioner 200 to be installed at a predefined orientation at itsinstallation site.

Spindle 204 has a bearing surface 212. In a present embodiment of theinvention, bearing surface 212 is generally conical in shape but thepresent invention is no so limited and cylindrical-shaped posts can alsobe used. Spindle 204 can be formed by die casting, or other suitablemanufacturing process, from a suitable material such as aluminum, whichshould not require further machining operations.

Tensioner 200 also includes a tensioner arm 216 to which a pulley 220 isrotatably affixed at one end thereof by a bolt 224. Pulley 220 rotatesabout a second axis. Pulley 220 can be designed to engage a flexibledrive such as a rubber belt, either toothed or smooth, or a chain.Pulley 220 includes a bearing 228, which can be integrally formed inpulley 220 or which can be press fit or otherwise mounted to pulley 220,and which abuts against a bearing face 232 of tensioner arm 216 to allowpulley 220 to rotate freely with respect to tensioner arm 216.Preferably, tensioner arm 216 is also formed by die casting, or othersuitable manufacturing process, from aluminum or other suitablematerials and thus should not require any further machining operations.

Tensioner arm 216 further includes a conical hub 236. Hub 236 receives aconical bushing 240 which acts between hub 236 and bearing surface 212to allow tensioner arm 216 to pivot about post 212 about a first axis.The first axis is parallel to and spaced from the second axis ofrotation.

Bushing 240, which can be best seen in FIG. 10, can be fabricated fromany suitable low friction, wear resistant material, such as Nylon 4/6(such as Stanyl TW363) and can be formed by injection molding or anyother suitable manufacturing process. The coefficient of friction of thebushing 240 can be modified as desired by adding filler materials suchas glass, graphite or by adding lubricants such as PTFE resins, drylubricants, etc.

The bushing 240 is either symmetrical (collar shaped as shown in FIGS. 7and 8) or asymmetrical as shown in FIG. 10. In either embodiment,undesired frictional drag between hub 236 and post 212 is reduced byhaving an axial extending spline-like bushing surface 244 over theportion of post 212 where the hubload vector is directed, i.e. where theload is expected to be applied from tensioner arm 216, and by having arecessed, or cut out, surface 248 over the non-load (or reduced load)bearing portion of post 212. In the illustrated embodiment, the cut outsurface 248 extends circumferentially about half.

Bushing surface 244 can include one or more outer axial grooves 252 toassist in removal of water or foreign material from between hub 236 andbearing surface 248 and/or to allow tuning of the frictional forcebetween hub 236 and post 212.

A biasing spring 256 surrounds post 212 and acts between spindle 204 andtensioner arm 216 to bias tensioner arm 216, and pulley 220, intotensioning engagement with the flexible drive tensioned by tensioner200. Preferably, spring 256 is formed of wire coils with a non-round,preferably rectangular, cross-section. As is known to those of skill inthe art, springs formed with coils of non-round cross section result insprings which produce a greater spring force than similar sized springsformed with coils of round cross sections, thus reducing the requiredoverall package volume for tensioner 200, for a given biasing force,compared to a tensioner with round cross section coils.

As discussed above, it is desired to provide some dampening betweenspindle 204 and tensioner arm 216 to achieve the desired operation oftensioner 200. Accordingly, a dampening structure, in this embodimentdampening shoe 260, is provided in tensioner 200. Dampening shoe 260 canbe fabricated from any suitable low friction, wear resistant organicbased material, such as Nylon 4/6 (such as Stanyl TW363) and can beformed by injection molding or any other suitable manufacturing process.

Dampening shoe 260 is located about post 212 against base 208.Preferably, dampening shoe 260 includes an inclined or spiral surface264 to receive spring 256. Base 208 includes a stop 270 at the end ofinclined surface 264 against which one end of spring 256 abuts.Similarly, tensioner arm 216 includes an inclined or spiral surface 274to receive spring 256. Inclined surface 274 includes a stop 278 againstwhich one end of spring 256 abuts.

By providing inclined or spiral surfaces 264 and 274, it is notnecessary to perform machining operations on spring 256 to flatten thetop and bottom of spring 256. If desired however, the present inventioncan also omit these inclined surfaces and utilize a spring 256 which hashad a machining operation, such as grinding, performed on its uppermostand bottommost coils to flatten their surfaces. Alternatively, inclinedsurfaces 264 and 274 can be omitted and spring 256 used withoutmachining its end surfaces flat, however this is less preferred as thedesired contact with the dampening shoe, described below, may not beachieved due to the resulting tilting of spring 256.

Similarly, by providing stops 270 and 278, it is not necessary toperform manufacturing operations to form tangs at the ends of spring 256thus potentially avoiding another machining operation, although such anadditional machining operation can be performed if desired.

As inclined surfaces 264 and 274 and stops 270 and 278 are formed duringthe die casting (or other suitable manufacturing process) of spindle 204and the die casting (or other suitable manufacturing process) oftensioner arm 216 and during the molding of dampening shoe 260, noadditional manufacturing expense is incurred in their provision apartfrom the incremental expense of the initial fabrication of the diesand/or molds, etc.

As pulley 220 and tensioner arm 216 are moved in the de-tensioningdirection, away from the flexible drive and against the biasing force ofspring 256, the diameter of the coils of spring 256 increase. Thisincrease causes the coils to press against an upstanding dampening shoewall 282 of dampening shoe 260 which is urged against the frictionsurface of inner wall 286 of tensioner arm 216. The squeezing andsliding of dampening shoe wall 282 between the outer surface of thecoils of spring 256 and inner wall 286 creates a variable frictionalforce which dampens the movement of tensioner arm 216 against thebiasing force of spring 256.

As will be apparent to those of skill in the art, as tensioner arm 216is moved in the tensioning direction, toward the flexible drive, thediameter of the coils of spring 256 decrease, allowing wall 282 ofdampening shoe 260 to disengage wall 286 of tensioner arm 216, reducing,and eventually substantially removing, the dampening force.

Thus, dampening shoe 260 and spring 256 provide an asymmetric dampeningforce greater in the de-tensioning direction than in the tensioningdirection, which is preferred for operation of a tensioner. Further, thedampening force increases, as tensioner arm 216 moves to a greaterextent, thus providing a position-dependent dampening force.

In addition to the cost savings available due to the avoidance ofadditional machining steps, one of the other perceived advantages of thepresent invention is the ease with which tensioner 200 can be assembled.First, dampening shoe 260 is placed on spindle base 208, bushing 240 isinstalled over post 212. Next, spring 256 is installed against inclinedsurface 264 and stop 270. Then tensioner arm 216 is installed overspring 256 and the end of spring 256 is located against stop 278.Finally, a thrust washer 290 and a front plate 294 are located on thetop of tensioner arm 216 on spindle 204 and spindle 204 is staked tofront plate 294. Pulley 220 can then be mounted to bearing face 232 viabolt 224 and assembly of tensioner 200 is complete. Tensioner 200 isinstalled on an engine or other device with a bolt (not shown) that isinserted through a central bore 302 in post 212.

As most tensioners are required to be in a partially pre-loaded statewhen being installed, during assembly spindle 204 can be held whiletensioner arm 216 is pivoted to a desired installation position and thena “grenade pin” 296, or other suitable device, can be inserted through anotch or bore 298 in tensioner arm 216 to engage a bore or groove 300 inspindle 204 to maintain tensioner 200 in the pre-loaded installationstate until grenade pin 296 is subsequently removed. If it is notrequired to provide tensioner 200 in a pre-wound state, grenade pin 296can be omitted.

Tensioner 200 employs a spindle 204 and a tensioner arm 216 which arepreferably manufactured by die casting, or other suitable manufacturingprocesses, negating a requirement for machining operations. Biasingspring 256 is preferably wound with wire coils having a non-circularcross section to increase the spring force of spring 256 compared to asimilar spring wound with wire of circular cross section. As tensionerarm 216 is moved in the de-tensioning direction, away from the flexibledrive, the diameter of the coils of spring 256 expands and the coilspress a portion of dampening shoe 260 into contact with wall 286 oftensioner arm 216 producing a dampening force. Tensioner 200 is simpleto assemble and requires a relatively small package volume for thebiasing force it can produce.

As should now be apparent, each of tensioners 20 and 200 providefrictional dampening of movement of tensioner arms 24 and 216respectively and a component of the frictional dampening force isvariable, depending upon the degree to which the respective tensionerarm has been rotated beyond an initial position. This variable componentis created when the expanding coils of the biasing spring abut a bearingstructure which is then subjected to an increased normal force,resulting in a commensurate increase in its frictional force. Further,the dampening force is not symmetric, increasing with a firstcharacteristic as the tensioner arm is moved in the de-tensioningdirection, away from the flexible drive, and decreasing with a secondcharacteristic as the tensioner arm returns in the tensioning directionto its initial position.

Tensioner 200 includes bearing 240 within the coils of its biasingspring 256, while tensioner 20 includes a bushing 60 surrounding thecoils of its respective biasing spring 84. While tensioner 200 allowsfor a somewhat more compact design, reducing the packaging volumerequired for tensioner 200, the greater bearing contact areas oftensioner 20 allow for greater loads to handled by tensioner 20, thusmaking tensioner 20 very suitable for high load applications such assynchronous drives in internal combustion engines, in addition toaccessory drive systems in such engines.

It is also contemplated that tensioner arms 24 or 216, or othercomponents of tensioners 20 or 200, can be treated to enhance theirthermal transfer capabilities, if desired. For example, a coating, suchas the thermal dispersant coating sold by Tech Line Coatings, Inc. ofMurrieta Calif. under the brand name TLTD, can be applied to the pointwhere bearings 36 or 228 mount to their respective tensioner arms 24 or216 to enhance the thermal transfer capabilities to remove waste heatfrom bearings 36 or 228. Similarly, the area of tensioner arms 24 or 216adjacent bushings 60 or 240 can be similarly treated to enhance theremoval of waste heat created by the frictional dampening forces at therespective bushings. It is contemplated that, if tensioner arms 24 or216 are manufactured from an engineering plastic, such thermaldispersant coatings will be particularly advantageous.

FIG. 12 shows an example of the asymmetry of the dampening force whichcan be obtained with tensioners 20 or 200. In the illustrated test case,a tensioner 20 with a tensioner arm 24 having a length one hundredmillimeters between the center of spindle 44 and bolt 32, was placed ina test rig. A force was then applied at bolt 32, in a directionsubstantially orthogonally to the length of tensioner arm 24, and theapplied force was plotted against the measured displacement of thetensioner arm.

As can be seen, the resulting force versus displacement plot is in theform of a hysteresis curve 300, demonstrating the asymmetric dampeningthat can be achieved. Specifically, when the tensioner is displaced fromabout 0.5 mm in the tensioning direction to about 0.5 mm in thede-tensioning direction (where 0.0. mm is an arbitrarily selectednominal midpoint for the tensioner's range of movement), the forcegenerated rapidly rises from about two hundred Newtons to about fivehundred and fifty Newtons, following the upper part of curve 300. As canbe seen, on this part of the curve the dampening force rises almostlinearly with the displacement until about five hundred and fiftyNewtons at the midpoint (0.0 mm), after which it is substantiallyconstant.

Conversely, when the tensioner is returned to the 0.5 mm initialposition in the tensioning direction, following the bottom part of curve300, the force on tensioner arm 24 rapidly drops almost linearly fromabout five hundred and fifty Newtons to about two hundred Newtons at themidpoint (0.0 mm), after which it is substantially constant.

For comparison purposes, plot line 304 shows a plot of the force versusdisplacement curve for tensioner 20 when the variable dampening features(namely dampening shoe 76) are removed. As can be seen, over the samerange of movement, the force generated by the tensioner arm 24 betweenthe same two extremes for undampened version of tensioner 24 rangesbetween three hundred and eighteen point five Newtons to three hundredand twenty one point five Newtons, i.e.—it is substantially constant.

The present invention provides a tensioner for flexible drives, such asaccessory drive systems or belt or chain synchronous drive systems oninternal combustion engines. The tensioners are compact and arerelatively economical to manufacture and assemble. In addition, thetensioners provide a dampening force to the tensioner arm which force isat least partially dependent upon the extent to which the tensioner armhas been rotated from an initial position, increasing the dampeningforce as the tensioner arm is moved further from the initial position.Further, the tensioners can provide an asymmetric dampening force,providing a relatively large dampening force when the tensionerinitially moves in the de-tensioning direction, and providing a rapidlydecreasing dampening force when the tensioner changes direction oftravel and then moves in the tensioning direction.

The above-described embodiments of the invention are intended to beexamples of the present invention and alterations and modifications maybe effected thereto, by those of skill in the art, without departingfrom the scope of the invention which is defined solely by the claimsappended hereto.

1. A tensioner for tensioning a flexible drive, comprising: a spindlehaving a base, said base configured for mounting on a surface of anengine; a tensioner arm mounted on said spindle for rotatable movementabout a first axis, said tensioner arm having a pulley rotatably mountedabout a second axis, said second axis being spaced from and parallel tosaid first axis; a coil spring acting between the spindle and thetensioning arm urging the tensioner arm to rotate about said first axisin a tensioning direction and bias the tensioner arm and the pulley intotensioning engagement with a flexible drive; a bushing mounted betweenthe tensioner arm and spindle to allow the tensioner arm to pivot aboutthe spindle and provide a first frictional force dampening movement ofsaid tensioner arm about said spindle; a dampening shoe mounted betweenthe spring and the tensioner arm, the dampening shoe being urged intoand out of frictionally engagement with the tensioner arm when coils ofthe coil spring radially expand and contract, respectively providing avarying second frictional force dampening movement of said tensioner armabout said spindle, said coils of said spring expanding as saidtensioner arm is urged in a direction opposite said tensioningdirection.
 2. A tensioner of claim 1 wherein said second variablefrictional force changes rapidly as the tensioner arm changes directionof movement
 3. The tensioner of claim 2, wherein one of said tensionerarm and said spindle has a cup structure surrounding said coil spring.4. The tensioner of claim 3, wherein said tensioner arm has a hub andsaid bushing is nested between said hub and said spindle.
 5. Thetensioner of claim 4, wherein said spindle has a first abutment engagingan end of said coil spring and said tensioner arm has a second abutmentengaging an opposite end of said coil spring, said dampening shoe beingpositioned 90° relative to said first abutment to receive a reactionaryforce generated by said coil spring.
 6. The tensioner of claim 5,wherein said first abutment supports said coil spring maintaininggeneral axial alignment of said coil spring as said tensioner armrotates relative to said spindle about said first axis.
 7. The tensionerof claim 6, wherein said shoe supports said coil spring maintaininggeneral axial alignment of said coil spring as said tensioner armrotates relative to said spindle about said first axis.
 8. The tensionerof claim 7, wherein said dampening shoe and said first abutmenthelically support a respective end coil of said coil spring.
 9. Thetensioner of claim 8, wherein said spindle has said cup structure andsaid hub surrounds said coil spring.
 10. The tensioner of claim 8,wherein said tensioner arm has said cup structure and said coil springsurrounds said hub
 11. The tensioner of claim 4, wherein dampening shoeis asymmetrically shaped having an arcuate shoe friction surface andsaid dampening shoe is fixed relative to said spindle whereby a reactivespring force is directed through said shoe friction surface.
 12. Thetensioner of claim 11, wherein said bushing is asymmetrically shapedhaving an arcuate bushing friction surface and said dampening shoe isfixed relative to said spindle whereby said reactive hubload force isdirected through said bushing friction surface.
 13. The tensioner ofclaim 12, wherein said spindle has said cup structure and said hubsurrounds said coil spring.
 14. The tensioner of claim 13, wherein saidtensioner arm has said cup structure and said coil spring surrounds saidhub
 15. The tensioner of claim 12, wherein said hub, said bushing andsaid spindle are tapered.
 16. The tensioner of claim 1, wherein saidcoil spring is formed from wire having a rectangular cross-section. 17.The tensioner of claim 16, wherein said tensioner arm is die cast. 18.The tensioner of claim 16, wherein bushing and said shoe are formed oflow friction, wear resistant material.
 19. The tensioner of claim 18,wherein said low friction, wear resistant material is NYLON 4/6.
 20. Thetensioner of claim 16, further comprising a pin extending between saidtensioner arm and said spindle to maintain a predetermined orientationfor shipping said tensioner, said pin being removable after thetensioner has been installed and said pulley engages said flexibledrive.
 21. The tensioner of claim 1, wherein a sum of said firstfrictional force and said second frictional force provide said tensionerwith variable damping.